ELECTRIC HOIST MODEL NO: CH2500B, CH4000B PART NO: 7630386, 7630391 OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS LS0517 - Iss 5
INTRODUCTION Thank you for selecting this Clarke Electric Hoist. The electric hoist is designed for lifting and lowering loads suspended on hooks over predetermined distances. Read this manual before use. The warnings and cautions in this manual help you operate the Electric Hoist safely. IMPORTANT Read all instructions carefully before you use this electric hoist. Pay attention to all sections of this User Guide that display warning symbols and notices. WARNING: THIS SYMBOL IS USED THROUGHOUT THE USER GUIDE WHEN THERE IS A RISK OF PERSONAL INJURY. MAKE SURE THAT THESE WARNINGS ARE READ AND UNDERSTOOD AT ALL TIMES. CAUTION: THIS SYMBOL IS USED THROUGHOUT THE USER GUIDE WHEN THERE IS A RISK OF DAMAGING YOUR ELECTRIC HOIST. MAKE SURE THAT THESE CAUTIONS ARE READ AND UNDERSTOOD AT ALL TIMES. GUARANTEE The pump is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Your receipt is required as proof of purchase. This guarantee is invalid if the electric hoist is found to have been abused, tampered with, or not used for the purpose for which it was intended. Faulty goods must be returned to their place of purchase, it must not be returned to us without prior permission. This guarantee does not effect your statutory rights. 2
CONTENTS Introduction...2 Important...2 Guarantee...2 Contents...3 Environmental Protection...3 General safety rules...4 Electrical Connections...5 Unpacking...6 Installation...6 Operation...7 Maintenance...8 Troubleshooting...9 Parts and servicing...9 Specifications...10 Exploded Diagram & Parts List...11 Declaration of conformity...13 Notes...14 Notes...15 ENVIRONMENTAL PROTECTION Through purchase of this hoist, the customer is taking on the obligation to deal with the WEEE in accordance with the WEEE regulations in relation to the treatment, recycling & recovery and environmentally sound disposal of the WEEE. In effect, this means that this hoist must not be discarded with general waste. Refer to the laws governing Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal facility. 3
GENERAL SAFETY RULES There is a serious risk of personal injury if you do not follow all instructions in this guide. 1. This hoist must only be used by a competent person who understands these instructions. 2. This hoist is for indoor, non-industrial use. 3. Keep children, animals and bystanders away from the work area. 4. Do not use this hoist if you are ill, tired, or under the influence of alcohol or drugs. 5. Before use, always examine the machine and its mountings to make sure that they are in good condition. If you find any damaged or broken parts, remove the hoist from service and renew or repair the part before further use. 6. Before use, it is important to make sure that the steel cable is correctly wound around the drum 7. Wear protective clothing, gloves, footwear and hard hat. 8. Do not wear loose clothing, jewellery and tie back long hair. 9. Protect the machine from frost and high temperatures. 10. If the capacity of the hoist is exceeded, the cutout will operate, Let the hoist cool down before using it again. 11. Make sure that the load is balanced, stable and that personnel stay clear of the raised load. 12. Speak to the Clarke service department for any spare parts relating to the hoist. 13. Make sure that the switches are in good condition. 14. Use this hoist for vertical lifts only. 15. Attach the hoist to a horizontal beam/box section that can hold the weight of the load and the hoist. 4
ELECTRICAL CONNECTIONS WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS FULLY BEFORE CONNECTING THE HOIST TO THE MAINS SUPPLY. This hoist is provided with a standard 13 amp, 230 volt (50Hz), BS 1363 plug, for connection to a standard, domestic electrical supply. Should the plug need changing, make sure that a plug of identical specification is used. WARNING: THE WIRES IN THE CABLE ARE COLOURED AS FOLLOWS: BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH If the colours of the wires in the power cable do not correspond with the markings on the terminals of your plug, proceed as follows. Connect the blue wire to the terminal which is marked N. Connect the brown wire to the terminal which is marked L. Connect the yellow and green wire to the terminal which is marked E or. Earth (Green and Yellow) Neutral (Blue) Plug must be BS1363/A approved. Always fit a 13 Amp fuse. Live (Brown) make sure that that the outer sheath of the cable is firmly held by the clamp AN APPROVED RESIDUAL CURRENT DEVICE (RCD) WHICH HAS A TRIPPING CURRENT OF LESS THAN 30MA MUST BE USED. If you are not sure, consult a qualified electrician. DO NOT try to do any repairs. 5
UNPACKING Unpack the box and make sure that the items in the list below are included. 1 x Hoist 1 x Hook / Pulley 2 x Bracket 1 x bag of fixings 1 x Instruction manual If a part is damaged, speak to your Clarke supplier immediately. INSTALLATION To attach the hoist to box section, use the brackets supplied. The box section must be able to hold the maximum load plus the weight of the hoist and brackets. If you are not sure, you must consult an approved engineer. 6
OPERATION HOIST CONTROL LIFT/LOWER BUTTON EMERGENCY STOP 1. Push the Lift button to lift the load. 2. Push the Lower button to lower the load. 3. To stop the hoist release the button. NOTE: The load will not stop immediately when you release the lower button. It can continue for a 3-4 mm before the brake takes effect. CAUTION: MAKE SURE THE HOIST HAS STOPPED BEFORE MOVING IN THE OPPOSITE DIRECTION. LIFT LOWER EMERGENCY STOP Push the emergency stop to stop the hoist in an emergency. The emergency stop can be reset by turning it clockwise until it pops out. TO USE YOUR HOIST WARNING: LIFTING OPERATIONS MUST BE PLANNED, SUPERVISED AND CARRIED OUT SAFELY BY COMPETENT PERSONNEL. Before use, make sure that the emergency stop and the lift/lower buttons are in good condition. 1. Play out the cable. Keep the cable in tension so that the coils on the drum remain neatly in place. 2. Attach the hook to the load, the hook must be placed - Directly above the centre of gravity of the load, and in line with the hoist. Make sure that nothing prevents a clean lift. 7
HOIST CAPACITY In the basic setup (shown on the right) the lifting capacity is 125 kg, (200 kg for the CH4000B) It is possible to increase the capacity to 250 kg (400 kg for the CH4000B). To do this: 1. Loop the cable around the pulley supplied. 2. Attach the hook to the hoist as shown. MAINTENANCE Unwind and examine the condition of the cable, for fraying, corrosion etc. Check the condition of all brackets, bolts and screws. NOTE: When in constant operation, the hoist must be inspected more frequently. 8
TROUBLESHOOTING PROBLEM CAUSE SOLUTION When you press the buttons the motor does not operate. Motor hums but does not lift Brake does not operate, and load slips The cable is twisted frayed or kinked The power cable is not plugged in correctly The cut out has operated Power failure The motor is too hot The load is more than the capacity of the hoist Brake has become stuck during storage. Brake is worn out Incorrectly wound on drum. The cable has been stored unwound or in bad conditions. Insert the power cable correctly Let the hoist cool down Check plug fuse Let it cool down Decrease the load Do not use the hoist and speak to your Clarke dealer for advice Do not use the hoist and speak to your Clarke dealer for advice Replace the cable. Replace the cable. If this does not solve your problem, please speak to the Clarke service department. See below PARTS AND SERVICING For Parts & Servicing, please contact your nearest dealer, or CLARKE International, on one of the following numbers. PARTS & SERVICE TEL: 020 8988 7400 PARTS & SERVICE FAX: 020 8558 3622 or e-mail as follows: PARTS: Parts@clarkeinternational.com SERVICE: Service@clarkeinternational.com 9
SPECIFICATIONS CH2500 CH4000 Load Capacity (Single Cable) 125 kg 200 kg Lifting Speed (Single Cable) 10 m/min 10 m/min Lifting Height (Single Cable) 12 m 12 m Load Capacity (Double Cable) 250 kg 400 kg Lifting Speed (Double Cable) 5 m/min 5 m/min Lifting Height (Double Cable) 6 m 6 m Cable Length 12 m 12 m Cable Diameter 3 mm 3.8 mm Duty Cycle S3 20% - 10min S3 20% - 10min Electrical Supply 230V @ 50Hz 230V @ 50Hz Power Rating 540 W 950 W Part Number 7630386 7630391 10
EXPLODED DIAGRAM & PARTS LIST 11
EXPLODED DIAGRAM & PARTS LIST No Description 1 Hexagon Bolt 2 Spring Washer 3 Flat Washer 4 Fixing Ring 5 Support Frame 6 Support Panel 7 Locating Shaft 8 Gear Shaft 9 Flat Washer 10 Gear (A) 11 Gear (B) 12 X-Head Bolt 13 Switch 14 Paper Washer 15 Limit Switch Plate 16 Flat Washer 17 Spring Washer 18 Nut 19 Cover 20 X-Head Bolt 21 Washer (1) 22 Washer (2) 23 Limit Pin 24 Driven Gear 25 Primary Gear 26 Pound Pin 27 Drum Shaft 28 Flat Key 29 Flat Key 30 Elastic Collar 31 Bearing 32 Screw No Description No Description 33 Gear Case 34 Spring Washer 35 Flat Washer 36 2nd Gear Wheel 37 Cushion Board 38 Front Cover 39 Bearing 40 Stator 41 Stator Shell 42 Rotor 43 Tripping Spring 44 Brake Disc 45 After Closure 46 Fan Blade 47 Fan Cover 48 Spring Washer 49 Flat Washer 50 Hexagon Bolt 51 Junction Box 52 Terminal 53 Cover 54 Holding Fixture 55 Holding Fixture 56 Safety Switch 57 Breaker Contactor 58 Locating Pin 59 Spring Tab 60 Cable 61 Socket 62 Holding Fixture 63 Handle Switch-Down 64 Condenser 65 Handle Switch -Up 66 Rise & Fall Switch 67 3-Prong Plug 68 Hook Locknut 69 Hook Washer 70 Hexagon Bolt 71 Hexagon Bolt 72 Pulley 73 Splint 74 Pulley 75 Locknut 76 1st Gearwheel 77 Flat Key 78 Gear Shaft 79 Bearing 80 Screw 81 Limiter 82 Hook 83 Rope Thimble 84 Wire Rope 85 Block 86 Aluminium Tube 87 Rope Drum 88 Wedge 89 Bushing When ordering any spare parts, please specify either RKCH2500 or RKCH4000 as required. 12
DECLARATION OF CONFORMITY 13
NOTES 14
NOTES 15